Toro 03800TE, REELMASTER 6500-D, 03801TE Operator's Manual

FORM NO. 3318-286 GB Rev A

®

MODEL NO. 03800TE—60001 & UP
MODEL NO. 03801TE—6

0001

& UP

REELMASTER

2- & 4-WHEEL DRIVE TRACTION UNITS

OPERATOR’S

MANUAL

®

6500-D

© The TORO Company 1995

Table of Contents

IDENTIFICATION & ORDERING 2
SAFETY INSTRUCTIONS 4
SYMBOL GLOSSARY 7
SPECIFICATIONS 10
BEFORE OPERATING 11

Check the Engine Oil 11
Check the Cooling System 11
Fill the Fuel Tank 12
Check the Hydraulic Fluid 12
Check the Planetary Gear Drive Oil 14
Check the Rear Axle Lubricant (Model 03801) 14
Check the Tire Pressure 14
Check Reel-To-Bedknife Contact 15

Check the Torque Of the Wheel Nuts 15
KNOW YOUR CONTROLS 16
OPERATING INSTRUCTIONS 18

Starting And Stopping 18

Priming Fuel System 19

Automatic Clip Control 19

Selecting Clip Rate (Reel Speed) 20

Clip Rate Selection Chart 21

Reel Control Light 22

Pushing or Towing Machine 22

Diagnostic Light 23

Diagnostic ACE Display 23

Checking Interlock Switches 24

Hydraulic Solenoid Valve Functions 26

Height-of-Cut Selection Potentiometer

Replacement 26

Operating Characteristics 27

MAINTENANCE 28

Greasing Bearings And Bushings 28
Service Interval Chart 29
Air Cleaner Maintenance 30
Engine Oil And Filter 31
Fuel System 32
Engine Cooling System 32
Engine Fan Belt 32
Changing Hydraulic Fluid 33
Replacing Hydraulic Filter 33
Checking Hydraulic Lines And Hoses 34
Adjusting Traction Drive For Neutral 34
Adjusting Cutting Unit Lift Rate 35
Adjusting Service Brakes 35
Changing Planetary Gear Drive Oil 35
Rear Wheel Toe-in 36
Fuses 37
Backlapping 37

PREPARATION FOR SEASONAL STORAGE 48

2

Safety

Training

1. Read the instructions carefully. Be familiar with the

controls and the proper use of the equipment.

2. Never allow children or people unfamiliar with these

instructions to use the lawn mower. Local regula­tions may restrict the age of the operator.

3. Never mow while people, especially children, or

pets are nearby.

4. Keep in mind that the operator or user is responsible

for accidents or hazards occurring to other people or
their property.

5. Do not carry passengers.

6. All drivers should seek and obtain professional and

practical instruction. Such instruction should empha­size:

• the need for care and concentration when work­ing with ride-on machines;

• control of a ride-on machine sliding on a slope
will not be regained by the application of the
brake. The main reasons for loss of control are:

– insufficient wheel grip;
– being driven too fast;

to be used and remove all objects which may be
thrown by the machine.

3. WARNING—Petrol is highly flammable.

• Store fuel in containers specifically designed
for this purpose.

• Refuel outdoors only and do not smoke while
refueling.

• Add fuel before starting the engine. Never
remove the cap of the fuel tank or add petrol
while the engine is running or when the engine
is hot.

• If petrol is spilled, do not attempt to start the
engine but move the machine away from the
are of spillage and avoid creating any source of
ignition until petrol vapors have dissipated.

• Replace all fuel tanks and container caps
securely.

4. Replace faulty silencers.

Operation

1. Do not operate the engine in a confined space where

dangerous carbon monoxide fumes can collect.

2. Mow only in daylight or in good artificial light.

– inadequate braking;
– the type of machine is unsuitable for its

task;

– lack of awareness of the effects of ground

conditions, especially slopes;

– ##incorrect hitching and load distribution.

Preparation

1. While mowing, always wear substantial footwear

and long trousers. Do not operate the equipment
when barefoot or wearing open sandals.

2. Thoroughly inspect the area where the equipment is

3. Before attempting to start the engine, disengage all

blade attachment clutches and shift into neutral.

4. Do not use on slopes of more than:

• Never mow side hills over 5°

• Never mow uphill over 10°

• Never mow downhill over 15°

5. Remember there is no such thing as a “safe” slope.

Travel on grass slopes requires particular care. To
guard against overturning:

• do not stop or start suddenly when going up or
downhill;

3

• engage the clutch slowly, and always keep the
machine in gear, especially when travailing
downhill;

• machine speeds should be kept low on slopes
and during tight turns;

• stay alert for bumps and hollows and other hid­den hazards;

• never mow across the face of the slope, unless
the lawn mower is designed for this purpose.

6. Use care when pulling loads or using heavy equip-

ment.

• Use only approved drawbar hitch points.

• Limit loads to those you can safely control.

14. Stop the engine and disengage the drive to the

attachment

• before refueling;

• before removing the grass catcher;

• before making height adjustments unless the
adjustment can be made from the operator’s
position.

• before clearing blockages;

• before checking, cleaning or working on the
lawnmower;

• after striking a foreign object. Inspect the
lawnmower for damage and make repairs
before restarting and operating the equipment.

• Do not turn sharply. Use care when reversing.

• Use counterweight(s) or wheel weights when
suggested in the instruction handbook.

7. Watch out for traffic when crossing or near road-

ways.

8. Stop the blades rotating before crossing surfaces

other than grass.

9. When using any attachments, never direct discharge

of material toward bystanders nor allow anyone near
the machine while in operation .

10. Never operate the lawn mower with defective

guards, shields or without safety protective devices
in place.

11. Do not change the engine governor settings or over-

speed the engine. Operating the engine at excessive
speeds may increase the hazard of personal injury.

15. Reduce the throttle setting during engine runout and,

if the engine is provided with a shutoff valve, turn
the fuel off at the conclusion of mowing.

Maintenance and Storage

1. Keep all nuts, bolts and screws tight to be sure the

equipment is in safe working condition.

2. Never store the equipment with petrol in the tank

inside a building where fumes may reach an open
flame or spark.

3. Allow the engine to cool before storing in any enclo-

sure.

4. To reduce the fire hazard, keep the engine, silencer,

battery compartment and petrol storage area free of
grass, leaves, or excessive grease.

5. Check the grass catcher frequently for wear or dete-

rioration.

12. Before leaving the operator’s position:

• disengage the power take-off and lower the
attachments;

• change into neutral and set the parking brake;

• stop the engine and remove the key.

13. Disengage the drive to attachments when transport-

ing or not in use.

4

6. Replace worn or damaged parts for safety.

7. If the fuel tank has to be drained, this should be

done outdoors.

8. Be careful during adjustment of the machine to pre-

vent entrapment of the fingers between moving
blades and fixed parts of the machine.

9. On multi-bladed machines, take care as rotating one

blade can cause other blades to rotate.

Sound & Vibration Levels

10. When the machine is to be parked, stored or left

unattended, lower the cutting means unless a posi­tive mechanical lock is used.

Sound Levels

This unit has an equivalent continuous A-weighted
sound pressure at the operator ear of: 82 dB(A), based
on measurements of identical machines per 84/538/EEC.

Vibration Levels

This unit has a vibration level of 2.5 m/s2at the posteri­or, based on measurements of identical machines per
ISO 2631 procedures.

2

This unit does not exceed a vibration level of 0.5 m/s
the posterior based on measurements of identical
machines per ISO 2631 procedures.

at

5

Symbol Glossary

Caustic liquids, 
chemical burns to 
fingers or hand

Crushing of 
whole body, 
applied from 
above

Cutting or 
entanglement of 
foot, rotating auger

Poisonous 
fumes or toxic 
gases, asphyxiation

Crushing of 
torso, force 
applied from side

Severing of 
foot, rotating 
knives

Electrical shock,
electrocution

Crushing of fingers 
or hand/, force 
applied from side

Severing of 
fingers or hand, 
impeller blade

High pressure
fluid, injection 
into body

force applied 
from side

Wait until all 
machine 
components have 
completely stopped 
before touching them

High pressure
spray, erosion of
flesh

Crushing of 
whole body

Severing of
fingers or hand, 
engine fan

High pressure
spray, erosion of
flesh

Crushing of 
head, torso and 
arms

Whole body entanglement, 
implement input drive line

Crushing of 
fingers

or hand, 

force

applied from 

above

Cutting of 
fingers or hand

Crushing of 
toes or foot, force
applied from above

Cutting of footCrushing of leg, 

Fingers or 
hand entangle-
ment, chain drive

Hand & arm
entanglement,
belt drive

Explosion Fire or open 

Shut off engine 
& remove key before 
performing mainten-
ance or repair work

Thrown or fly-
ing objects, whole
body exposure

flame

Riding on this 
machine is allowed 
only on a passen-
ger seat & only if the 
driver’s view is not 
hindered

Thrown or 
flying objects, 
face exposure

Secure lifting 
cylinder with locking 
device before getting 
in hazardous area

Consult 
technical manual 
for proper service 
procedures

Runover/back-
over, (relevant 
machine to appear 
in dashed box)

Stay a safe 
distance from 
the machine

Fasten seat belts Safety alert 

Machine tipping, 
riding mower

Stay clear of 
articulation area 
while engine is 
running

Machine rollover,
ROPS (relevant 
machine to appear 
in dashed box)

Stored energy
hazard, kickback
or upward motion

Do not open 
or remove safety 
shields while 
engine is 
running

triangle

Do not step on 
loading platform if 
PTO is connected to tractor 
& engine is running

outline safety
alert symbol

Hot surfaces, 
burns to fingers 
or hands

Do not step

Read operator’s 
manual

6

Eye protection
must be worn

Head protection
must be worn

Hearing
protection must
be worn

Caution, toxic
risk

First aid

Flush with water Engine Transmission

Fire, open light
& smoking
prohibited

Level
indicator

Engage Disengage

Horn Battery charging

Hydraulic
system

Liquid level Filter Temperature Failure/

Attachment
lower

condition

Hourmeter/elapsed
operating hours

Brake system

Oil Coolant (water) Intake air Exhaust gas Pressure

Malfunction

Attachment
raise

Fast Slow Continuous

Spacing distance Snow thrower,

Start switch/
mechanism

collector auger

variable, linear

On/start Off/stop

Plus/increase/
positive polarity

Volume empty Volume full

Minus/decrease/
negative polarity

Machine travel
direction,
forward/rearward

Jack or
support point

Draining/
emptying

Control lever
operating
direction, dual
direction

Control lever
operating
direction, multiple
direction

Engine lubricat­ing oil

Clockwise
rotation

Engine lubricating
oil pressure

Counter-clock­wise rotation

Engine lubricating
oil level

Grease
lubrication
point

Engine lubricating
oil filter

Oil lubrication
point

Engine
lubricating oil
temperature

Lift point

Engine coolant

7

Engine coolant
pressure

Engine coolant f
ilter

n/min

Engine failure/
malfunction

Transmission
failure/malfunction

Engine rotational
speed/frequency

Clutch Neutral High Low Forward Reverse Park

231

First gear Second gear

Engine
lubricating oil
pressure

Choke Primer (start aid) Electrical preheat

Engine intake/
combustion air

Engine intake/
combustion air
pressure

(low temperature
start aid)

Engine intake/
air filter

Transmission oil Transmission oil

Engine start Engine stop

pressure

Transmission oil
temperature

NHLFRP

Third gear (other #'s
may be used until
the maximum # of for­ward gears is reached.)

Hydraulic oil Hydraulic oil

Hydraulic oil
pressure

Hydraulic oil level Hydraulic oil filter

temperature

Hydraulic oil
failure/malfunction

Headlights Lock Unlock Differential lock 4-Wheel drive Power Take-Off Power Take-Off,

Reel cutting
element, height
adjustment

Parking brake Fuel Fuel level Fuel filter Fuel system

Traction Above working

temperature range

Drilling Manual metal arc

0430 weight Do not dispose

welding

in the garbage

failure/malfunction

Manual 0356 Water pump

CE logo

Diesel fuel Unleaded fuel

rotational speed

Reel cutting
element

0626 Keep dry

8

Specifications

Engine: Peugeot, 4-cylinder, 4-cycle, overhead cam, 116
cu. in (1.9 liter) displacement liquid-cooled diesel engine.
38 hp (28 kW); governed to 2500 rpm high idle; 23.5:1
compression ratio, 3.27" (83 mm) bore x 3.46" (88 mm)
stroke. Automatic glow plug/starter interlock system.
Heavy-duty, 2-stage, remote air cleaner.

Main Frame: All-welded formed steel frame, includes
tie-down loops.

Cooling System: Rear-mounted, cross-flow agricultural
type radiator; 7 fins per inch. 7.1 liter capacity. Air to
oil cooler mounted to the rear of the radiator tips outward
for cleaning. Removable oil cooler/radiator screen.

Fuel System: Rotary fuel injection pump with energized­to-run (ETR) fuel flow solenoid. Replaceable spin-on
fuel filter/water separator with water sensor. Fuel capaci­ty: 64 liter.

Traction System: Servo-controlled hydrostatic system
driving double-planetary, gear-reduction, front-wheel dri­ves. Foot pedal control of forward/reverse ground speed.

Toro 4-MaticR 4-Wheel Drive System only: Rear drive
axle coupled to hydrostatic transmission via an overrun­ning clutch for full-time, on-demand 4-wheel drive. A
Roll Over Protective Structure and seat belt are standard.

Ground Speed: 0–10 mph forward; 0–4 mph reverse.

Cutting Unit Drive System: Reel motors feature quick

disconnect for removal or installation onto the cutting
unit. Cutting units can be driven from either end.

Seat: Deluxe high-back suspension seat with adjustable
fore and aft travel, weight and height. Tool box at the left
side of the seat.

Steering System: Power steering with dedicated power
source.

Tires: Two rear steering tires: 20 x 10.00–10, tubeless, 6­ply rating. Two front traction drive tires: 29 x 12.00–15
tubeless, 6-ply rating. Recommended tire pressure for
front and rear tires is 15–20 psi.

Brakes: Individual totally enclosed, multi-disc, wet brakes
and parking brakes on front traction wheels. Hydrostatic
braking through traction drive.

Electrical Features: 12-volt, 530 cold-cranking amperes
at 0° F (–18° C), 85-minute reserve capacity at 80° F (27°
C), maintenance-free battery. 55-amp alternator with l° C
regulator/rectifier. Automotive-type electrical system. Seat
switch, reel and traction interlock switches.

Controls: Foot-operated traction and brake pedals. Hand
operated throttle, speed control lever, parking brake lock,
ignition switch with automatic preheat cycle, single joy
stick control for cutting unit on/off and lift lower. Cutting
unit backlap switch under the operator's seat. Height-of-cut
selector knob located under the control panel.

Gauges: Hour meter, speedometer, fuel gauge, temperature
gauge, 4-bank warning lamp: oil pressure, water tempera­ture, amps, and glow plug. 2-bank warning lamp: water in
fuel, water level.

Diagnostics; The Automatic Control Electronics, ACET
system allows precise timing and control of machine func­tions for maximum reliability. Toro standard diagnostic
display connects to an electronic control unit to pinpoint
any electrical problems quickly and easily. Available
DATA LOGT system allows mechanic to find intermittent
problems.

General Specifications (approx.):

Width-of-Cut: 244 cm
Overall Width:
Transport 213 cm
Operational 279 cm
Overall Length: 305 cm
Height:

Without roll-over protection system installed:152 cm
With roll-over protection system installed: 213 cm

Weight:

Model 03800 1,194 kg*
Model 03801 1,232 kg*

*With 5-Blade Cutting Units & full fluid levels

9

Before Operating

CAUTION

Before servicing or making adjustments to the machine,
stop the engine and remove the key from the switch.

CHECK THE ENGINE OIL (Fig. 2 & 3)

Crankcase capacity is 5 l with filter.

➀

1. Park the machine on a level surface. Release the hood latch

and open the hood.

2. Remove the dipstick from the tube cap, wipe clean and rein-

stall the dipstick into the tube cap. Pull it out again and check
the oil level on the dipstick: The oil level must always be in the
notch area on the dipstick.

3. If the oil level is low, remove the tube cap and add SAE 15W-

40 CD oil until the level reaches top of notch on the dipstick.
DO NOT OVERFILL.

4. Install the oil tube cap.

5. Close the hood and secure the latch.

CHECK THE COOLING SYSTEM (Fig. 4)

CAUTION

If the engine has been running, pressurized hot coolant
can escape and cause burns if the degasser cap is
removed. Allow the engine to cool at least 15 minutes or
until the degasser cap is cool enough to touch without
burning your hand.

1. Hood latch

Figure 2

➀

Figure 3

1. Dipstick/tube cap

➀

Capacity of the system is 13 l.

Check the cooling system if the low water level light illuminates.

1. Park the machine on a level surface. Release the hood latch

and open the hood.

10

1. Degasser tank

Figure 4

2. Remove the degasser tank cap and check the coolant level. The

level should be up to or above the tabs in the degasser tank,
when the engine is cold.

3. If coolant is low, remove the degasser tank cap and add a 50/50

mixture of water and Peugeot-recommended anti-freeze (Toro
Part No. 93-7213). DO NOT USE WATER ONLY OR ALCO­HOL/METHANOL BASE COOLANTS.

4. Install the degasser tank cap.

5. Close the hood and secure the latch.

FILL THE FUEL T ANK (Fig. 5)

Fuel tank capacity is 56 liters.

1. Remove the fuel tank cap.

2. Fill the tank to about one inch below the top of the tank (not

the filler neck) with No. 2 diesel fuel. Then install the cap.

➀

Figure 5

1. Fuel tank cap

DANGER

Because diesel fuel is flammable, use caution when stor­ing or handling it. Do not smoke while filling the fuel
tank. Do not fill the fuel tank while the engine is run­ning, hot, or when the machine is in an enclosed area.
Always fill the fuel tank outside and wipe up any spilled
diesel fuel before starting the engine. Store fuel in a
clean, safety-approved container and keep the cap in
place. Use diesel fuel for the engine only; not for any
other purpose.

CHECK HYDRAULIC FLUID (Fig. 6)

The hydraulic system is designed to operate on anti-wear hydraulic
fluid. The machine’s reservoir is filled at the factory with approxi­mately 32 liters of Mobil 424 hydraulic fluid. Check the level of
hydraulic fluid before the engine is first started and daily thereafter.

Group 1 Hydraulic Fluid (Recommended for ambient temperatures

consistently below 38° C.):

➀

ISO type 46/68 anti-wear hydraulic fluid

Mobil Mobil Fluid 424
Amoco Amoco 1000

1. Hydraulic tank cap

Figure 6

11

International Harvester Hy-Tran
Texaco TDH
Shell Donax TD
Union OIl Hydraulic/Tractor Fluid
Chevron Tractor Hydraulic Fluid
BP Oil BP HYD TF
Boron OIl Eldoran UTH
Exxon Torque Fluid
Conoco Power-Tran 3
Kendall Hyken 052
Phillips HG Fluid

Note: The fluids within this group are interchangeable.
Group 2 Hydraulic Fluid (Biodegradable):
ISO VG 32/46 anti-wear hydraulic fluid

Mobil EAL 224 H

Note: The fluid in this group is not compatible with the fluids
in group 1.

IMPORTANT: These hydraulic fluids are specified to allow
optimal operation of the machine in a wide range of tempera­tures encountered. The group 1 fluids are a multi-viscosity
hydraulic fluids which allows operation at lower temperatures
without the increased viscosity, which is associated with straight
viscosity fluids.

Note: When changing from one type of hydraulic fluid to the other,

be certain to remove all the old fluid from the system, because
some brands of one type are not completely compatible with
some brands of the other type of hydraulic fluid.

IMPORTANT: Use only types of hydraulic fluids specified.
Other fluids could cause system damage.

Note: A red dye additive for the hydraulic system fluid is available

in 20 ml bottles. One bottle is sufficient for 15–23 l. of
hydraulic fluid. Order Part No. 44-2500 from your Authorized
Toro Distributor

1. Position the machine on a level surface, lower the cutting units

and stop the engine.

2. Clean the area around the filler neck and the cap of the

hydraulic tank. Remove the cap from the filler neck.

3. Remove the dipstick from the filler neck and wipe it with a

clean cloth. Insert the dipstick into the filler neck; then remove
it and check the level of fluid. Fluid level should be within 0.6
cm of the mark on the dipstick.

12